Method of coating roofing material



1953 e. A. FASOLD EIAL METHOD OF COATING ROOFING MATERIAL 2 Sheets-Sheet1 Filed April 7, 1950 I l l l l I ll Illll l ATTORNEYS.

D 1, 1953 a. A. FASOLD ET'AL METHOD OF COATING ROOFING MATERIAL 2Shets-Sheet 2 Filed April 7, 1950 Z/swr Fae:

INVENTORS. GEOQGE A l-TasaLa f/awmm 1 0441.404,

ATTORNE YS Patented Dec. 1, 1953 UNITED STATS GFFICE METHOD OF COATINGROOFING MATERIAL Application April 7, 1950, Serial No. 154,528

3 Claims. 1

Our invention relates to plastic coated and plastic formed buildingmaterial which may be briefiy described as prepared roofing for use inmaking roofs or other parts of buildings.

Our invention relates to a prepared roofing construction and a methodand machine for making such construction in which mineral surfacinggranules of varying hue, chroma and color value are embedded likemosaics in the exposure surfaces of roofing units. It is our object toso arrange the areas of distribution of the granules on the roofingunits that when they are laid on a roof or wall, illusory shadow effectsare produced. These optically accentuate relief effects so that higherrelief is simulated than that physically present.

In our method of manufacture and in the prepared roofing manufacturedthereby, it is our object to so control the three color variables thatan aesthetically pleasing eiiect is produced.

The first variable of colored mineral granules is hue by which the lightwaves reflected from the surface are dominated by and may be measured interms of hue like red, blue, yellow or mixtures thereof. The secondvariable is chroma by which the various hues are more or less intense orpure, and are measured in terms of admixture with whites, grays, andblacks. Finally the color value is the visual effect of hue and chromameasured in terms only of dark and light. Thus all colored surfaces havehue, chroma and color value. A black and white surface has only colorvalue.

It is an object of our invention to embed mineral granules in batches ofpredetermined variance of hue, chroma, and value on the areas of theexposure surface of prepared roofing, such as shingles, with adjacentareas blended together so that, when the shingle units are laid on aroof, an optical effect of deep shadows below the butts of the shingleunits is produced simulating shingles of greater than actual thickness,the blending of adjacent areas on which the batches of predeterminedhue, chroma and color value are embedded, being such that bandingeffects are minimized and irrespective of the hue and chroma, the colorvalue of each exposed shingle unit gradually deepens or darkens frombutt to overlap. As a variant of this arrangement we may, by reversingthe control, cause the shingle unit to gradually become lighter in colorfrom butt to overlap.

Another object of our invention is to employ granules having differenthues and chroma wherein the color value is such that banding efiects areavoided. For example, in a strip shingle predominantly blue in color,reddish brown granules may be used to give an interesting contrast inhue, the color value being such that there is no abrupt change in colorvalue and the optical illusory shadow effect is produced even though thehue and chroma of the granules vary widely. Copyrighted Roof Designs asare made possible with our new method and machine, are depicted inCopyrights Cl. G, form G, 12,907, 12,908, 12,909 and 12,910, registeredJune 19, 1949. The specific example illustrated in the drawing explainsthe detailed technique of making the roof design 12,908 Green ShadowBlend Roof Design. Of course, other colors may be used to make designsof varying hues and chroma while maintaining the principle of the shadowblend color value effect.

It is an object of our invention to apply to the roofing sheet batchesof granules of various hues and chroma on the principle described ofblending color value by dropping the granules by gravity in bands on aweb of asphalt coated roofing material as it is conveyed through theroofing machine and controlling the areas of distribution of thegranules by various means which will he described.

In the drawings:

Figure l is a plan view, partly diagrammatic, of a preferred type ofgranule distributing machine.

Figure 2 is a side elevation, also partly diagrammatic, of the mechanismas shown in Figure '1.

Figure 3 is a plan view of a web as roofing material after the granuleshave been applied, the cross hatching and shading indicating areas ofdifferent hues, chroma and color value.

Figure 4 is a plan view on an enlarged scale, of a shingle unit such asmay be cut from the web shown in Figure 3.

The mechanism involved is an adaptation and modification of themechanism of What is known in the industry as the Norwood Blender,various modifications of which appear in the expired patents to RobertMaclean No. 1,574,835, 1,774,988, 1,794,719 and 1,857,463 to whichreference is hereby made. The broad purpose of such machines has been todistribute mineral granules of diiierent hues over the surface of a webof asphaltic coated roofing material so as to provide a series ofdiiferently colored areas having a somewhat regular defined pattern andwith fairly sharp division lines between such areas. So far as we areaware, the arrangement of granule distribution on a web 01 shinglematerial so that when the web is cut into shingles, irrespective of thehue and intensity of the granule colors in the various areas, an efiectof shadow blending in the exposure portions of the shingles i achieved,is new in the art, although in his Patent 2,036,329 Giles suggests thisachievement by spraying applications of paint in a prescribed pattern toa shingle web surface.

Referring to the drawings, the web of shingle material impregnated andcoated with an asphaltic surfacing material to which mineral granuleswill adhere and become partially embedded is indicated at l in Figure 2,the travel being in the direction of the arrow. The travel of the web isup over a surfacing roll 2 which compresses the granules distributed onthe web into embedment with the web coating. The excess of granules overand above those embedded into the web by the surfacing roll 2 iscollected off the roll by the deflector plate 3 and falls into bin IS.The web passes up over the roller 4 and from thence to the coolinglooper which forms no part of this invention.

The bins in which the granules of different hue, chroma and value aredistributed are indicated at 5, 6, l, and 8 and in order to explainspecifically how the web, which in the drawings is indicated as fourfeet in width, has the granules distributed on it, we may assume thatbin #5 is filled with a mixture of 3 parts dark (bluish) green granulesand 1 part light (bluish) green granules. Bin #ii is filled with medium(yellowish) green granules. Bin #1 is filled with a mixture of 3 partsdark (bluish) green granules- Bin #8 and one part shiny jet blackgranules. is filled with dark (bluish) green granules. The granules inthe difierent bins are of different hue and chroma, but they havesubstantially the same color value.

The discharge of granules from the bins is controlled by cam and clutchmechanisms (not shown) which cause intermittently timed rotation of thefeed rollers 5A, 6A, 1A and 8A during certain predetermined intervals.Under normal conditions each roller operates for a period when therotation of the other rollers is inhibited thereby depositing a band ofgranules, the areas of which vary in hues and chromas but. not in colorvalues.

In Figure l the rectangular areas at thebottom of the bins indicateblocks 5B, 6B, 1B and 8B which block ofi the delivery of granulesexcepting through the slots 5C, 60, 1C and 8C. These slots remain openand direct the flow of granules onto the conveyor belt 9 when therespective feed rollers 5A, 6A, 7A and 8A are in operation.

The granules bounce on the belt and bafile in a heterogeneouslydispersed pattern due to their irregular shape. This causes the adjacentbands to blend into one another. The granules from the bins in hands onthe conveyor belt 9 are discharged onto the inclined plate Ill which isat such an angle that the granules do not pile up but discharge at thebottom of theincline at about the same rate as they are received fromthe conveyor belt 9.

Before reaching the asphaltic web the granules in bands of varying hueand chroma have mixed at their edges on each side, granules of sharplycontrasting color value. Thus the bin I l is subdivided into set ofshort bins. These are indicated by the double horizontal lines in Figurel. The bins marked I 2 of which there are four, have discharge slots HA.The bins marked l3 4 have discharge slots ISA. The compartments, blockedoff at the bottoms by the blocks MA contain no granules.

We fill the bins I2 with shiny jet black granules and the bins I3 withlight color value granules. The feed roller 15 is normally in constantoperation and continuously feeds black. granules from the bins 12 intofour bands staggered with relation to the bands on which the granulesfrom bins 5 to 8 are deposited. The feed roller 15 also feeds thegranules of light color value in a band staggered between the bands fromthe bins 5 to 8.

Fromthe bin II the black granules from comertments l2 and the lightgranules from the compartments l3 fall onto the inclined plate 10 andblend at the edges of the bands, this blending being accomplished by theheterogeneous bouncing of the granules on the baffle plate producing adispersion of the granules into adjacent color bands thus forming acombination of color areas having no sharp edge delineations.

In bin marked IS the spill-over granules from surfacing roll 2 areconstantly distributed over the entire surface of the web through thefeed slot 11. The granules from the bin it drop onto the inclined platel8 from which they are deposited over the entire surface of the web ofshingle material.

Referring now to Figure 3, the entire width of the web of shinglematerial is shown with the various bands for making strip type shingleswhich when laid on a roof produce the Green Shadow Blend Roof designregistered in CODY- right Class G. No. 12,908 June 10, 1949. It will benoted that the distribution of mixed hues and chroma occupy the bandsmarked Blend. Between the bands marked Blend are the bands marked LightEdge and outside the bands marked Blend are the bands marked DarkShadow.

The hopper ll spills only light edge and dark shadow granules. Thespaces marked I4 are the blocks to confine granules to, the spaces. [2.

and 13. Bin it which is spilling; constantly, covers the entire sheetalso covers the area outside the bands with the mixture. These areas aremarked Mixture and it will be understood-that when strip shingles areout from the web the reasmarkecl Mixture will bethe upper portion ofeach strip shingle which when. laid will be covered over by overlappingshingles. It is the exposure areas of the shingles in which the shad owblend effect is produced.

When the web is cut into two pairs of op posed. edge shingles along thevlines I9I9' of Figure 3, an individual strip shingle like thatillustrated in Figure 4 will be produced. The upper end of the slots 20mark the upper area of the exposure portions of each shingle. The loweror butt end of each shingle will be light and intermediate the lightbutt area and the dark upper exposure edgev there will appear aconstantly variable group of different huecl: granules having differentchroma but all having.

substantially the same color value. In order to control the areas ofdistribution of the granules from the hoppers 5 to 8, it is arranged sothat.

distribution fromv these hoppers does not match up with the width of thestrip shin les. Thus in Figure 3 the width of a strip shingle isindicated by the lines 2-2, while the repeat pattern of distributionfrom. the hoppers 5 to. 8 is indicated by the lines 11-12. In order toshow this more clearly the areas of the Blend bands in Figure 3 carrythe numbers of the bins from which the granules in the different binsare derived. Thus there is a constant repeat of the area patterns 5, 6,l and 3 in regular sequence on a band the length of which is aboutone-half longer than the width of the individual strip shingles.

Thus it Will be observed that no one shingle is similar in thearrangement of color areas on it to any other shingle. At the same timethe shadow effect at the covered area of each shingle is dark and thebutt edge is light, the intermediate area being a constantly changingblend of granules of different hue and chroma. The color value issimilar to the Guild Building Roof as set forth in application fordesign patent Ser. D. 3,640 filed June 30, 1949.

For producing different arrangements, as for example shingles with darkbutts and light overlap areas, all that is necessary is to change thegranules in the compartments I2, l3, putting the dark granules in thecompartments l3 and the light granules in the compartments it. While thesimulation of deep shadows caused by an arrangement of shingles on theroof with light butts contrasted. against dark underlying portions ismore effective, much the same efiect is produced with dark butts againstlight underlying shingles. In each case the apparent thickness of theshingles is accentuated.

While the machine described and the method of distributing granules isbroadly explained as depositing certain types of granules in what arecalled bands and areas, it should be clearly understood that the methodof spilling the granules on a conveyor and spilling the granules fromthe conveyor so that they bounce on the inclined deflector plates,causes an intermingling of the granules both widthwise of the web andlengthwise which completely obliterates sharp edge delineations. A roofhaving the strip shingles laid entirely haphazard has a constantvariation in hue, chroma and value to a sufficient extent to obliterateany visual effect of what is called banding.

The individual shingle units or tabs of a strip shingle may havegranules applied which vary not only in hue and chroma but also in valuebetween adjoining shingles or tabs of the strip in a course on the roof.The granules may be applied so as to exhibit this variation in colorvalue on the individual tabs. The range and variation in color value mayalso be exhibited lengthwise of the strip. Such variation is shown inthe copyrighted roof designs previously referred to.

Having thus described our invention, what We claim as new and desire tosecure by Letters Patent is:

1. A method of distributing mineral granules on a web of roofingmaterial to provide at least two rows of shadow blend strip shingles inopposed butt edge relationship which consists in feeding along anasphaltic coated web in tacky condition, depositing on the tacky web, ina series of bands spaced to form the middle exposure portions of thestrip shingles in each row, batches of granules of predetermined uniformcolor value in heterogeneously mixed areas having blended end edges, thegranules in said areas having distinctly diflerent chromatic values withsubstantially the same color value, depositing in bands adjacent toopposed side edges of the first referred to bands, and which will formthe overlapping areas of the opposed strip shingles in each row,granules of darker color value than.

the granules of the first noted band while controlling the deposition toproduce edge blending with the side edges of the first referred tobands, depositing in double width bands adjacent to the opposite sideedge of the first referred to bands and which will form the butts of theopposed strip shingles in each row granules of lighter color value thanthe granules of the first noted band while controlling the deposition toproduce edge blending with the opposed side edges of said first referredto bands, pressing the deposited granules into the coated web and thencutting the web forming rows of oppositely arranged strip shinglesmedially of said doublewidth bands to provide strip shingles which whenlaid on a roof will produce an optical effect of deep shadow below thebutts of the shingle units of each strip without an optical effect ofhanding.

2. A method of distributing mineral granules on a Web of roofingmaterial to provide at least two rows of shadow blend strip shingles inopposed butt edge relationship which consists in feeding along anasphaltic coated web in tacky condition, depositing on the tacky web, ina series of bands spaced to form the middle exposure portions of thestrip shingles in each row, batches of granules of predetermined uniformcolor value in heterogeneously mixed areas having blended end edges, thegranules in said areas having distinctly different chromatic values withsubstantially the same color value, depositing in bands adjacent toopposed side edges of the first referrcd to bands, and which will formthe overlapping areas of the opposed strip shingles in each row,granules of darker color value than the granules of the first noted bandwhile controlling the deposition to produce edge blending with the sideedges of the first referred to bands, depositing in double width bandsadjacent to the opposite side edge of the first referred to bands andwhich will form the butts of the opposed strip shingles in each rowgranules of lighter color value than the granules of the first notedband while controlling the deposition to produce edge blending with theopposed side edges of said first referred to bands, pressing thedeposited granules into the coated web, collecting such granules as arenon-adherent to the coated web and distributing them uniformly over theentire surface of the web, and then cutting the web forming rows ofoppositely arranged strip shingles medially of said double width bandsto provide strip shingles which when laid on a roof will produce anoptical eifect of deep shadow below the butts of the shingle units ofeach strip without an optical effect of banding,

3. A method of distributing mineral granules on a web of roofingmaterial to provide at least two rows of strip shingles, having changingcolor value depthwise of the exposure areas of the shingle units, inopposed butt-edge relationship, which consists in feeding along anasphaltic coated Web in tacky condition, depositing on the tacky web, ina series of bands spaced to form the middle exposure portions of thestrip shingles in each row, batches of granules of pre-determineduniform color value in heterogeneously mixed areas having blended endedges, the granules in said areas having distinctly different chromaticvalues with substantially the same color value, depositing in bandsadjacent to opposed side edges of the first referred to bands, and whichwill form the overlapping areas of the opposed strip shingles in eachrow, granules of a color value different in one direction from andcontrasting with the color value of the granules of the first notedband, while controlling the deposition to produce edge blending with theside edges of the first referred to bands, depositing in double widthbands adjacent to the opposite side edge :of the first referred to bandsand which will form the butts of the opposed strip shingles in each rowgranules of a color value different in the other direction from andcontrasting with the color value of the granules of the first notedband, while controlling the deposition to produce edge blending with theopposed side edges of said first referred to bands, pressing thedeposited. granules into the coated web and then cutting the web formingrows of oppositely arranged strip shingles medially of said double widthbands to provide strip shingles which when laid on a roof will producean optical effect of enhanced shingle thickness below the butts of theshingle units of each strip without an optical effect of handing.

GEORGE A. FASO-LD. HOWARD E. CALLAHAN.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date Becker Apr. 30, 1912 Becker Apr. 30, 1912 Wright June 22, 1915Overbury Sept. 21, 1915 McKay Dec. 12, 1916 Elvidge May 2, 1922 ElvidgeOct. 31, 1922 Overbury May 6, 1930 Cumfer June 27, 1933 Wettlaufer Sept.26, 1933 Levin May 29, 1934 Freegard Apr. 16, 1935 Harshberger May 7.1935 Penley Mar. 16, .1937 Penley Oct. 18, 1938 Howell Jan. 14, 1941

1. A METHOD OF DISTRIBUTING MINERAL GRANULES ON A WEB OF ROOFINGMATERIAL TO PROVIDE AT LEAST TWO ROWS OF SHADOW BLEND STRIP SHINGLES INOPPOSED BUTT EDGE RELATIONSHIP WHICH CONSISTS IN FEEDING ALONG ANALIPHATIC COATED WEB IN TACKY CONDITION, DEPOSITING OF THE TACKY WEB, INA SERIES OF BANDS SPACED TO FORM THE MIDDLE EXPOSURE PORTIONS OF THESTRIP SHINGLES IN EACH ROW, BATCHES OF GRANULES OF PREDETERMINED UNIFORMCOLOR VALUE IN HETEROGENEOUSLY MIXED AREAS HAVING BLENDED END EDGES, THEGRANULES IN SAID AREAS HAVING DISTINCTLY DIFFERENT CHROMATIC VALUES WITHSUBSTANTIALLY THE SAME COLOR VALUE, DEPOSITING IN BANDS ADJACENT TOOPPOSED SIDE EDGES OF THE FIRST REFERRED TO BANDS, AND WHICH WILL FORMTHE OVERLAPPING AREAS OF THE OPPOSED STRIP SHINGLES IN EACH ROW,GRANULES OF DARKER COLOR VALUE THAN THE GRANULES OF THE FIRST NOTED BANDWHILE CONTROLLING THE DEPOSITION TO PRODUCE EDGE BLENDING WITH THE SIDEEDGES OF THE FIRST REFERRED TO BANDS, DEPOSITING IN DOUBLE WIDTH BANDSADJACENT TO THE OPPOSITE SIDE EDGE OF THE FIRST REFERRED TO BANDS ANDWHICH WILL FORM THE BUTTS OF THE OPPOSED STRIP SHINGLES IN EACH ROWGRANULES OF LIGHTER COLOR SHINGLES IN EACH ROW GRANULES OF THE FIRSTNOTED BAND WHILE CONTROLLING THE DEPOSITION TO PRODUCE EDGE BLENDINGWITH THE OPPOSED SIDE EDGE OF SAID FIRST REFERRED TO BANDS, PRESSING THEDEPOSITED GRANULES INTO THE COATED WEB AND THEN CUTTING THE WEB FORMINGROWS OF OPPOSITELY ARRANGED STRIP SHINGLES MEDIALLY OF SAID DOUBLE WIDTHBAND TO PROVIDE STRIP SHINGLES WHICH WHEN LAID ON A ROOF WILL PRODUCE ANOPTICAL EFFECT OF DEEP SHADOW BELOW THE BUTTS OF THE SHINGLE UNITS OFEACH STRIP WITHOUT AN OPTICAL EFFECT OF BANDING.